Installation

INSTALLATION

NOTE: If a new intake manifold is being installed, transfer all necessary components onto new manifold.

1. Clean sealing surfaces of intake manifold and cylinder heads.
2. Position intake manifold gaskets on cylinder heads.

NOTE: Before installation, inspect intake manifold gaskets for nicks, cuts and/or deformation. If gaskets show no sign of damage they may be reused.

3. Position intake manifold on cylinder heads.

NOTE: Ensure alignment tabs on gasket are aligned with holes in cylinder head.

4. Install and tighten nine bolts in sequence shown to 20-30 Nm (15-22 lb ft).

Intake Manifold:

5. Inspect and if necessary replace O-ring seal on thermostat housing. Position thermostat housing and upper hose and install two bolts and tighten to 20-30 Nm (15-22 lb ft).
6. Connect heater supply hose.
7. Connect both HO2S sensors.
8. Connect vacuum hose to throttle body elbow vacuum port.
9. Connect and if necessary adjust throttle valve cable.
10. Install accelerator cable bracket on intake manifold and connect accelerator and speed control cables to throttle body.
11. Install PCV valve in camshaft cover and connect canister purge solenoid vent hose.
12. Connect air conditioning compressor, HDR sensor, and purge solenoid.
13. Connect 42-pin connector on retaining bracket on vacuum brake booster.
14. Install 42-pin connector on retaining bracket on vacuum brake booster.

42-Pin Connector Bracket:

15. Raise vehicle.
16. Connect EGR tube to RH exhaust manifold and tighten line nut to 35-45 Nm (26-33 lb ft).
17. Connect EVO sensor and oil sending unit.
18. Tighten oil filter an additional 1/2 turn after seal contact.
19. Lower vehicle.
20. Position alternator and install two retaining bolts. Tighten to 20-30 Nm (15-22 lb ft).
21. Install two bolts retaining alternator brace to intake manifold and tighten to 8-12 Nm (6.0-8.8 lb ft).
22. Connect alternator wiring harness to alternator, RH fender apron and junction block.
23. Position ignition wire assembly on engine and install two bolts retaining ignition wire tray to coil brackets. Tighten bolts to 8-12 Nm (6.0-8.8 lb ft).
24. Connect eight ignition wires to ignition coils in positions shown.

Ignition Wire Position:

25. Connect all ignition wires to spark plugs.
26. Connect ignition wire brackets on camshaft cover studs.
27. Connect both ignition coils and CMP sensor.
28. Install accessory drive belt if necessary.
29. Install air inlet tube.
30. Install wiper module.
31. Connect fuel lines.
32. Connect negative battery cable.
33. Fill and bleed cooling system.
34. Start engine and check for leaks.
35. Check and add oil as required to bring to specified level.